Charging apparatus and portable power supply

ABSTRACT

A portable battery box is described. The portable battery box is suitable for charging and housing a battery and comprises: a housing having a lid, a battery removably disposed within the housing, an inverter, a computer processing system, and a display screen. The computer processing system is configured to be powered by the battery and used for receiving measured charge parameters of the battery and estimating other battery parameters.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of, and claims priorityto, nonprovisional U.S. patent application Ser. No. 13/192,245, filedJul. 27, 2011, which claims priority to Australia patent Application No.2010903353, filed Jul. 27, 2010, which are all hereby incorporated byreference in their entirety as examples.

FIELD OF THE INVENTION

The present invention relates generally to portable battery boxessuitable for housing and charging batteries. In certain applications,lead acid batteries are housed in the portable battery boxes. Aspects ofthe present invention relate generally to methods of monitoring andcontrolling the charging and discharging of batteries within portablebattery boxes, as well as associated software, hardware, data processingapparatus, computer readable memories and computer program elements forcharging and discharging the batteries within those boxes.

BACKGROUND TO THE INVENTION

Portable battery boxes which are suitable for deployment of electricalpower in convenient forms and in remote locations are known. In thoseknown portable battery boxes, batteries are disposed in housings for theprotection of the batteries and recharged in those housings. Theadvantages of the battery boxes include that the boxes protect thebatteries themselves, componentry associated with charging anddischarging, and that the housings facilitate ease of handling andreduce potential for injury to users.

However, monitoring the recharging of the batteries disposed in thebattery boxes is inflexible and difficult in known models of portablebattery box, in that there is little useful information about thecharging process indicated. Furthermore, in some known devices, thecharging is ineffective. There may be several reasons for thesedifficulties. First, a charging method applied to some types ofbatteries is not always effective for other types of batteries,depending on the chemical composition of the battery and other factors,and if the battery in the box is changed to a different type, thecharging may be ineffective. In addition, in some box designs, access tothe battery terminals is inhibited by some structural member or, on theother hand, the terminals are not adequately protected, and thus exposedto users which is dangerous.

Also, the batteries are heavy and lifting known battery boxes by theirlids can cause deformation of selected areas of the box, which can causethe release of connecting cleats and clips and the like, which mayrelease the battery from the box or release corrosive fluid from thebattery into surrounding areas or worse, onto users.

Known battery boxes also include limitations and in controls andmonitoring devices.

The present inventors have developed an improved charging apparatus inthe form of a battery box, which may ameliorate one or more of anyabovementioned disadvantages.

DISCLOSURE OF INVENTION

According to a first aspect of the present invention there is provided aportable battery box suitable for charging and housing a battery, theportable battery box comprising:

a charging apparatus for charging a battery;

a main body for housing a battery, the main body including a base wall,a top wall and at least one side wall extending between the base and topwalls; and

at least one handle disposed in a respective one of the side walls ofthe main body.

Preferably the main body includes a covering lid which comprises a topwall and a downwardly-depending skirt, the arrangement being such thatthe downwardly-depending skirt extends to form a hollow lid shell havinga rim at an opening of the hollow lid shell to form a lid chamber.Similarly, a hollow base shell is provided, so that a base chamber isprovided having a rim, the chamber being adapted to house a battery. Thelid and base shells may be roughly equal in size, and preferably the lidshell is about ⅓ the size of the base shell.

When assembled together the rims of the shells are operatively connectedtogether so that the hollow lid shell hinges to open, the hinge beingmounted on one wall and at an opposite wall they are fastened togetherwith a clasp to close the main body.

Preferably the at least one handle is disposed in the hollow base shellside wall, so that a lifting force is transmitted through the side wallof the base shell when the battery box is being lifted by the at leastone handle. This obviates a separation force which would be experiencedat the clasp if the handle were in the lid.

Preferably two handles are provided, and each handle of the two isdisposed in end wall portions of the base shell side wall. Preferablythe or each handle includes a surface which corresponds generally to auser's finger which in use is inserted into the side wall and disposedat a slight angle to the wall. The surface is thus arranged to include abase ramp angled upward and inward and a radiused head portion at anupper end of the ramp to receive an end of a finger and to thus providefinger support.

Preferably the handles include apertures to allow cooling air fromoutside the box into the hollow base shell and hollow lid shell.Preferably the apertures are disposed in the radiused head portion ofthe handle so that water will be inhibited from flowing through theapertures.

Preferably the ramp and radiused head portion of the or each handle areinset or recessed into the end walls so that an external wall of thehandle is substantially or generally flush with the end wall.

Preferably the covering lid is detachable from the main body. Preferablythe covering lid is stackable within other covering lids to reducevolume in transportation. Preferably the main body is also stackablewithin other main bodies to reduce volume in transportation. Preferablythe side walls of the hollow shells taper outwards slightly towardstheir respective rims to facilitate stacking.

In a second aspect, the present invention provides a portable batterybox suitable for housing and recharging a battery when installed, thebattery box comprising:

a main body for housing a battery, the main body including a base wall,a top wall and at least one side wall extending between the base and topwalls;

a charging apparatus for charging a battery;

one or more electrical access ports suitable for control of and/ormonitoring of and/or supply or discharge of electrical power to thebattery, the or each electrical access port mounted adjacent one or moreof the side, base or top walls so that they are recessed therefrom; and

one or more access covers, each access cover for covering a respectiveelectrical access port so that by actuating the or each access cover theelectrical access ports may be accessed and wherein the cover isgenerally flush with the side, base and/or top wall.

Preferably the or each electrical access port is mounted in one or morerecesses set in from its respective side, base or top wall. In apreferred embodiment the or each access cover is a closure suitable toclose the one or more recesses. Preferably there are several recessesand several access covers. Further preferably the or each access coverincludes a seal to seal the recess so as to inhibit water ingress to theelectrical access ports. In some arrangements the seal is disposed on aperimeter of the recess associated with the wall.

Preferably the main body includes a covering lid which comprises a topwall and a downwardly-depending skirt, the arrangement being such thatthe downwardly-depending skirt extends to form a hollow lid shell havinga rim at an opening of the hollow lid shell to form a lid chamber.Similarly, a hollow base shell is formed, so that a base chamber isprovided having a rim, the chamber being adapted to house a battery. Thelid and base shells may be roughly equal in size, and preferably the lidshell is about ⅓ the size of the base shell. When assembled together therims of the shells are hinged along one wall and at an opposite wallthey are fastened together with a clasp to close the main body.

Preferably the electrical access ports are selected from the groupconsisting of: an LCD display; a plurality of user input/output keys; amouse or trackball; an isolation switch; a USB port; a 6, 12 or 24V DCcigarette lighter/alternative power source slot; a 110V/60 Hz or 240V/50Hz General Power Outlet; a 50 A Anderson plug slot; and a plurality of6, 12, 24V battery posts.

Preferably the or each access cover extends over a portion of the topwall to a portion of an adjacent side wall so that the or each accesscover is in the form of a gullwing-like shell. Preferably the accesscovers are hinged. Preferably the hinge is disposed on the top wall endof the access cover.

Preferably a lip or tab which extends from a portion of the access coveris provided to facilitate operation of the access cover. In a preferredembodiment the lip is on the opposite end of the access cover to that onwhich the hinge is mounted.

The or each access cover may include a window or may be whollytransparent so as to allow viewing of the control and/or monitoringand/or outlet devices without opening the or each access cover.

In use battery is provided in the main body and in use is disposedwithin the chamber. Preferably the battery is a lead-acid battery andmay be any one of a suitable kind of lead-acid battery, includingconventional wet-type, calcium-calcium (MF), AGM or gel battery.

In a third aspect, the present invention provides a portable battery boxsuitable for recharging and housing a battery, the battery boxcomprising:

a main body for housing a 12 v or 24V battery, the main body including abase wall, a top wall and at least one side wall extending between thebase and top walls;

a charging apparatus for charging a 12V or 24V battery;

an inverter; and

a general power outlet for AC output to power household devices.

Preferably the main body includes a covering lid which comprises a topwall and a downwardly-depending skirt, the arrangement being such thatthe downwardly-depending skirt extends to form a hollow lid shell havinga rim at an opening of the hollow lid shell to form a lid chamber.Similarly, a hollow base shell is formed, so that a base chamber isprovided having a rim, the chamber being adapted to house a battery. Thelid and base shells may be roughly equal in size, and preferably the lidshell is about ⅓ the size of the base shell.

When assembled together the rims of the shells are hinged along one walland at an opposite wall they are fastened together with a clasp to closethe main body.

Preferably the battery is removable by opening the covering lid andremoving the battery from the chamber in the hollow base shell.

Preferably the inverter is removably mounted in the portable batterybox.

In a fourth aspect, the present invention provides a method ofmonitoring a charging or discharging operation of a battery in usedisposed in a portable battery box according to the first, second orthird aspects of the present invention, the method including the stepsof:

measuring first charging and/or discharging parameters at selected timeintervals;

estimating selected other charging parameters at selected timeintervals; and

displaying the charging or discharging parameters on a display screenassociated with the battery box, the charging or discharging parametersbeing selected from the group consisting of: battery voltage; chargingstatus; time to charge completion; time to discharge completion;condition of the battery; battery charging current; battery dischargecurrent.

The display may be activated by receiving input from a user interface.Preferably the user interface is an information key adapted to bedepressed to activate. Preferably the display is activated by a chargeinput at the external power socket, or when a device is otherwiseplugged into one of the electrical access ports.

In a fifth aspect, the present invention provides a data processingapparatus for charging a battery in a portable battery box, the dataprocessing apparatus including:

a central processing unit (CPU);

a memory operatively connected to the CPU, the memory containing aprogram adapted to be executed by the CPU, wherein the CPU and memoryare operatively adapted to receive an input voltage value of a batteryin use disposed in the battery box and estimate a battery capacity valueassociated with the battery and send the capacity value to a displayscreen for display to a user.

In a sixth aspect, the present invention provides a computer programelement comprising a computer program code to make a programmabledevice:

measure and store a voltage of a battery in use disposed in a portablebattery box;

estimate a battery capacity value associated with the battery based onthe measured battery voltage; and

display the battery capacity value on a display screen.

Preferably the estimate step includes the step of consulting referencemaps which contain values of charge capacity corresponding to selectedvoltage values.

Preferably the estimate step also includes calculating time remainingfrom an algorithm which utilises the charge capacity from the referencemaps.

In a seventh aspect, the present invention provides a computer readablememory encoded with data representing a programmable device comprising:

means for receiving a battery voltage value measured across batteryterminals of a battery in use disposed within a portable battery box inaccordance with a first, second or third aspect of the presentinvention;

means for estimating the battery capacity based on the measured voltagevalue; and

means for sending a display signal to a display so as to display thebattery capacity.

Preferably the display screen is an LCD display screen.

Preferably the memory is configured to log history of charge anddischarge.

Preferably the method includes the step of remembering the type of leadacid battery disposed in the portable battery box for a selected periodof time.

In an eighth aspect there is provided a portable battery box suitablefor housing and charging a battery, the battery box comprising a mainbody for housing a lead acid battery, the main body including a basewall, a top wall and at least one side wall extending between the baseand top walls; and a plurality of different electrical output ports anda charging apparatus for charging a battery.

In a ninth aspect there is provided a portable battery box suitable forhousing and charging a removable battery including a display screen forthe purpose of monitoring the charging of the battery.

Throughout this specification, unless the context requires otherwise,the word “comprise”, or variations such as “comprises” or “comprising”,will be understood to imply the inclusion of a stated element, integeror step, or group of elements, integers or steps, but not the exclusionof any other element, integer or step, or group of elements, integers orsteps.

Any discussion of documents, acts, materials, devices, articles or thelike which has been included in the present specification is solely forthe purpose of providing a context for the present invention. It is notto be taken as an admission that any or all of these matters form partof the prior art base or were common general knowledge in the fieldrelevant to the present invention before the priority date of theinvention disclosed in this specification.

In order that the present invention may be more clearly understood,preferred embodiments will be described with reference to the followingdrawings and examples.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an isometric view of a portable battery box suitable forcharging and portably housing a battery in a closed position inaccordance with a preferred embodiment of the present invention, showingtop, front and right end walls.

FIG. 2 shows another isometric view of the portable battery box of FIG.1 in a closed position showing top, front and left end walls;

FIG. 3 is an isometric view of the portable battery box of FIG. 1showing access covers and lid in an opened position;

FIG. 4 is another isometric view of the portable battery box of FIG. 1from a different viewing angle showing the access covers and lid in anopen position;

FIG. 5 is a detail view of a user interface and display;

FIG. 6 is a plan view of the portable battery box of FIG. 1;

FIG. 7 is a right end elevation view of the portable battery box of FIG.1;

FIG. 8 is a view of the display of FIG. 5 showing a charging displaymessage;

FIG. 9 is a view of the display of FIG. 5 showing a discharging displaymessage;

FIG. 10 is a flowchart schematic connection diagram of the chargingapparatus of FIG. 1; and

FIG. 11 shows a preferred embodiment of a method of monitoring a batteryin a battery box.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings there is shown a portable battery boxgenerally indicated at 10 and suitable for charging and housing abattery 14 when it is disposed within the battery box 10. The portablebattery box 10 includes a main body 9 comprising a hollow base shell 12which itself includes a base wall 16, opposed end walls 17 and 19, andopposed front and back walls 13 and 15, the opposed walls extending fromthe base wall 16 to a hollow base shell rim 11 which provides an opening21 through which the battery can be placed so as to be disposed within ahollow chamber 23 for storage within the base shell 12.

The main body 9 includes a covering lid 20 which is in the form of ahollow lid shell 21 and includes a top wall 18 and a skirt dependingtherefrom, the skirt having opposed end walls 117, 119 and opposed frontand back walls 113 and 115. The lid shell is operatively connected toopen and close via a hinge on a back of rims 11 and 111. The opposedwalls extend towards a lid rim 111 which, when the lid 20 is in a closedposition, abuts the hollow base shell rim 11. The lid 20 is adapted toreceive and mount control and monitoring electronic devices so as tofacilitate their protection from water ingress. The lid shell alsoincludes an interior panel 23 in order to provide structural support andto further cover battery charge and control electronics from water andother fluid ingress thereto.

The main body 9 also includes a fastener in the form of a clasp or latch30 so as to fasten the hollow base shell rim 11 and the hollow lid rim111 to one another when the shells are in a closed position. The clasp30 is disposed along a front wall of the two rims at an intermediateposition.

Electrical access ports 40 are provided and are operatively connected tothe battery so as to control the charging or discharging of the batteryand/or monitor selected parameters of the battery 14 or provide power toor from the battery. The electrical access ports 40 are mounted so as tobe disposed adjacent one or more of the top, side, or end walls of thelid shell 21 and are recessed therefrom. In preferred embodiments atleast an operational or control or user interface portion of theelectrical access ports 40 is recessed from one of the walls. Theelectrical access ports 40 are mounted so as to be disposed within arecess set in from a wall.

The electrical access ports 40 include an LCD display 41, a plurality ofuser input keys or a mouse or trackball 42, an isolation switch 43, aplurality of USB slots 44, an external power supply socket 25, a DCcigarette lighter/alternative power source 45, a 240V or 110V AC GeneralPower Outlet (GPO) 46, a 50 A Anderson plug 47 and a pair of DC batteryposts (6, 12 or 24V) 48.

The DC battery posts 48 are disposed at a left-hand end of the lid shell21 to facilitate ease of connection and access.

The LCD Display 41, user input keys 42, cigarette lighter sockets 45 andUSB slots 44 are arranged along a front, top wall of the lid shell 21for ease of user operation.

The hollow lid shell includes access covers 50, 51, 52 in order to coverthe electrical access ports 40. The access covers 50, 51, 52 extend fromthe top wall to an adjacent side or end wall so that each forms agullwing- or similar other curved shape and are movable from a closedposition (shown in at least FIG. 1) to an open position (shown in atleast FIG. 4). When the access cover 50 is in the closed position theelectrical access ports 40 are substantially sealed and substantiallyprotected from damage and inadvertent operation, for example, whenpacked in tightly in a boot or trunk of a vehicle with other items. Theseal may be disposed on the cover or on the wall which the cover abutswhen in the closed position.

When the access cover 50, 51, 52 is in the open position the electricalaccess ports 40 may be accessed and actuated.

The access covers 50, 51, 52 include hinges 53 and extend from the topwall 18 to a depending wall (113, 115, 117, or 119). The hinges 53 aredisposed at the top wall end. A detent is provided to hold the accesscover 50, 51, 52 in the open position and the hinges naturally tend toreturn the access covers to a closed position under the influence ofgravity once a user releases them from the detent hold.

The access covers 50, 51, 52 may include a window or may be whollytranslucent or transparent for ease of viewing the electrical accessports 40.

The hollow base shell 12 includes handles 70 which are disposed in thewalls 17 and 19 of the base shell 12 so that when lifting the batterybox 10, the lifting forces are taken substantially in a plane which issubstantially parallel to the walls of the hollow base shell and notthrough the lid shell 21 and clasp 30. The handles 70 are integratedwith the wall, in that they are recessed so that at least a face wallportion of the handle 70 is substantially flush with the wall 17 or 19.

The handles 70 include apertures 71 to facilitate cooling air fromoutside the battery box 12 into the chamber 23 for cooling the battery14 and the electrical access ports 40. The handles include a surfacewhich cooperates with a finger such that a ramp is provided to guide afinger into a radiused head portion disposed at an upper end of theramp, the arrangement including a slight overhang. The apertures 71 areis disposed in an upper portion of the radiused overhang so that watermay be inhibited from ingress to the chamber 23 through the apertures.

A cooling fan 60 is provided to cool the battery 14 and/or itselectrical access ports 40. The cooling fan 60 is mounted in the lidleft-hand wall 117. The fan 60 in operation, draws air in from theoutside through the handle apertures and out through the lid or theother way around, depending on conditions.

The hollow lid shell 21 and hollow base shell 12 are adapted to bestackable within other lid shells and base shells to reduce volumeduring transport. The walls of the shells may flare or taper outwards tofacilitate stacking.

Further control devices provided include an inverter and a batterycharging unit (not shown). The battery charging unit may be powered froma 110 v or 240 v AC power source, a 12 v or 24V DC power source oranother suitable power source. The inverter may be removably mounted inthe battery box. These devices and the other control devices generallyare mounted in the lid portion 20 so as to inhibit water ingress totheir componentry and to facilitate access thereto by users.

The battery 14 is removably held in place when disposed in the chamber23 by a hook and loop strap fastener arrangement which when deployedextends across an upper face of the battery 14.

The portable battery box 10 also includes the charging apparatus whichcomprises a processing system for charging and conditioning the battery14. Any suitable form of processing system may be used. For example, theprocessing system includes at least a processor, a memory, one or moreinput/output devices, such as for example data ports, other device inputport or sensor port, and/or user input buttons 42 and display 41, allcoupled together via a bus or other coupling device(s).

Accordingly it will be appreciated that the processing system may beformed from any suitable processing system, such as for example asuitably programmed PC, PCB, PLC, internet terminal, laptop, hand heldPC or the like which is typically operating applications software toenable processing, data transfer and in some cases web browsing.

Among other things, the memory stores two reference voltage maps—a firstmap, being a charging map, and a second map, being a discharging map.The processor is caused by the software to consult these maps from timeto time so as to assess the condition of the battery and to display thatbattery condition during charging and/or discharging on the display 41.Example charge maps are shown in the table below and comprise an arrayof battery condition percentage values which correspond to selectedvoltage values. The charge maps thus indicate to the processor thebattery capacity level expressed as a percentage, when the processor hasreceived a battery charge value.

Charge Map Discharge Map  0% 10.8 V  0% 10.8 V 10% 11 V 10% 11 V 20%11.4 V 20% 11.2 V 30% 11.8 V 30% 11.4 V 40% 12.2 V 40% 11.6 V 50% 12.6 V50% 11.8 V 60% 13 V 60% 12 V 70% 13.2 V 70% 12.2 V 80% 13.4 V 80% 12.4 V90% 13.6 V 90% 12.6 V 100%  13.8 V 100%  12.8 V

The processor is then caused to display the percentage capacity of thebattery. The processor also is caused to calculate the time expecteduntil the battery is fully charged or discharged, from the capacityinformation and from other data it is able to receive, such as thecurrent draw or current input, (or a net current draw or net currentinput, if current is being both drawn and input). The algorithm for thecalculations is described hereinafter.

Preferably a PCB will be used to process the above information andcharge and condition the battery 14.

User input buttons or keys 42 include: Up Button 61; Down Button 62;“OK” Button 63; Information button 64.

Schematic connections are shown in FIG. 10 and which show how the PCBconnects with other elements of the battery box. That is, The AC mainsare shown at 87 which connect to a switch mode power supply 90 and theexternal power supply socket 25. The socket 25 is connected to aprocessor in the form of a PCB 89. The PCB 89 is connected to userinterfaces which are in the form of information button 64 and “OK”button 63 and an LCD display 41. A switch/mode button 84 is an input tothe processor 89. Outputs from the processor are in the form of USB port87. Outputs from the battery 14, also connected to the processor 89 arean inverter 83 and 240V power outlet 81, an Anderson outlet 47 throughan isolation switch 96, and further 12V cigarette lighter outlets 45.

EXAMPLE

In operation the processing system controls the charging andconditioning of the battery and monitors and displays the chargeinformation for users in accordance with the description herein andshown in FIG. 11.

To charge, a plug from an external power supply is inserted into theexternal power supply socket 25 for charging. The external power supplyexpects 24V and 6 A DC when in use.

The processor begins in a ready state and waits for charge input fromthe external power supply socket 25 or a user input key 42.

A sensor in the processing system detects the presence of a chargingvoltage at the external power socket. The processor may cause thedisplay 41 to read a welcome message: “Welcome to the ARK SmartPowerpack. Please select battery type and press OK” [or similar].

The processor will cause the display to request the input of a batterytype, by showing the following message or one like it:

Standard flood-type Lead Acid Battery

Gel Battery

Calcium Battery

AGM Battery

The processor waits until the user has toggled through the above list ofbattery types using the up/down buttons 61/62 until the selected batterytype is highlighted and then waits for the user to press OK to confirmthe battery type.

The processor then requests that the battery size (in terms of Ah) isthen input by the user or selected from a list which is caused to bedisplayed on the display 41. This quantity may then be used in acalculation by the software to assess battery charge remaining asdescribed herein.

For example, if Gel battery is selected, the processor will cause thedisplay to read: “Gel Battery selected. Charging commenced” [orsimilar].

The processor then causes the charging apparatus to commence a selectedspecific charging program for that battery type by introducing aselected amount of charge from the external power supply socket 25 tothe battery terminals in a selected manner in accordance with a selectedcharging cycle programmed into the processing system. The chargingprograms are described below.

During charging the processor will cause the screen to display themessage on display 41 shown in FIG. 8. The processor is caused to updatethe display 41 after a selected time period has elapsed, which inpreferred embodiments is every 15 minutes.

The message caused to be displayed on the display 41 changes dependingon the selected charging cycle which as discussed above depends on thetype of battery selected.

Charging

If a plug is inserted into the external power supply socket 25 thesoftware will recognize that it should switch to charging mode, and willselect one appropriate charging cycle, so as to function as set outbelow. The processor will measure and receive the battery voltage andthen will be caused to select from a charge, conditioning or Bulkcharging cycle accordingly, as is known to a person skilled in the art.

During charging the processing system causes the display 41 to displayup to four qualities during charging—selected from, among other things,charging current (expressed in Amperes), discharge current (expressed inAmperes), cycle type, battery condition, voltage, and time remaining tofull charge or full discharge.

For example, during a Charge Cycle, which is until the battery reaches12.5V, the following qualities are caused to be displayed:

-   -   (a) Charge Cycle    -   (b) Battery condition expressed as a percentage of full (minor        units in 1% increments)    -   (c) Battery Voltage expressed in units of Volts. (minor units in        0.1V increments) and    -   (d) Number of hours to full charge or discharge expressed in        hours

The information button is the same as the on/off button—holding it downfor an extended time will actuate the system, while touching theinformation button briefly will force a test.

Note: Hours are expressed in 0.5 hr increments

During Charge cycle, if battery does not reach 12.5 voltage after 25hours the processor will cause the display to read a message such as forexample “Alarm. Faulty battery.”

During a Boosting cycle wherein the processor maintains a constantvoltage to the battery terminals for a period of 5 hours the processorcauses the display 41 to display the following properties:

(a) Boosting Cycle

(b) Battery condition expressed as a percentage of fully charged

(c) Battery Voltage expressed in volts

(d) number of hours to go before fully charged

If battery fails to reach approximately 12.5V after 25 hours theprocessor will cause the display to read an alert message such as forexample “Alarm. Faulty Battery” and then will cause the charger tocommence a charging cycle known as a Conditioning cycle.

During a Conditioning cycle wherein the processor causes the battery tocharge by maintaining constant voltage to the battery terminals at acurrent of approx 0.1 A the processor causes the display to display thefollowing qualities:

(a) Conditioning (float) Cycle

(b) Battery condition expressed as a percentage of fully charged

(c) Battery Voltage expressed in Volts

Note: this cycle will maintain the constant battery voltage for 500hours

Testing

During charging, the processor is caused by the software, at selectedtime intervals, preferably 15 minutes, to stop charging the battery andrest the battery for a rest period. The rest period is for approximately20 seconds. The processor, at the end of the 20-second rest period, iscaused to detect the voltage across the terminals of the battery 14. Theprocessor is then caused to compare that measured voltage value to areference voltage stored in the charging map. The reference voltagecorresponds with a figure on the charging map which is a percentagecharge in the battery and the processor is caused to display thatpercentage charge on the display 41.

The processor is caused to select the charge map based on a net currentflow value. That is, the processor is caused to measure the current flowin through the external power socket and the current flow out throughthe other ports or battery outlet, and makes a decision as to whichcharging map to consult, based on the net current flow.

The charging map and the discharging map are different to reflect thatthe battery capacities under charge differ under charge and discharge sothis distinction is preferred to be made so the calculation is moreaccurate. For example, a battery with 90% charge might correspond to12.6V under discharge conditions but a battery with 90% charge mightcorrespond to 13.6V under charge conditions. Differing batteries havedifferent charge maps.

The time until full charge is calculated using the quantities of:

-   -   a) battery capacity value from the reference map    -   b) the total battery capacity when full    -   c) current flow in

in accordance with the equation below:

${(a)\mspace{14mu}{{Timeremaining}({hrs})}} = \left( \frac{\%\mspace{14mu}{charge} \times {Ahcapacity}}{Currentnow} \right)$

That is:

Timeremaining=number of hours remaining until full discharge or charge

% charge=battery capacity remaining, taken from charge map

Ahcapacity=battery capacity when full, expressed in Ampere hours

Currentnow=net current to the battery ie charge current−strap current(flowing from the battery).

A similar equation is utilised for calculating time to discharge.

In between the 15-minute scheduled tests, the software receives currentflow (Ampere) information at more frequent intervals from ammetersdisposed to measure input current and output current and updates thedisplay to display charge remaining percentage estimate figures.

Discharging

Default mode for the charging processor system is discharge mode. Whenpower is detected at the external power supply socket 25, the unit willcommence charging, however, if there is a net outflow of charge, thedisplay may show a time to discharge. That is, during net dischargingthe processor will recognize that the battery is in net discharging modeand will display a discharge message on the display 41 which is shown onFIG. 9.

Also, when the information button is pressed during discharging i.e. anappliance is connected though one of the outlets, such as the USB port,or GPO or Anderson port or DC battery posts, the processor will causethe display 41 to show:

-   -   (a) battery condition expressed as a percentage of fully charged    -   (b) Battery Voltage expressed in volts    -   (c) Number of hours at the present discharge rate remaining        before the battery is fully discharged.

Unlike charging, the 15 minute rest stops are not caused to occur in netdischarge mode. The processor is caused to constantly monitor(continuously, or every few seconds or milliseconds) the battery chargeacross the terminals while the battery 14 is discharging. The batteryvoltage measurement is compared with the discharge reference map.

A thermocouple is provided and connected to the processing apparatus. Ifthe internal temperature of the box exceeds a selected temperature theprocessor will cause the display to read “warning—overtemperature” [orsimilar] and to sound a buzzer.

If the wires are connected to the wrong terminals the screen will read“wires connected to wrong battery terminals, reverse polarity tocommence charging”. A buzzer sounds a warning.

The processing apparatus stores the selected battery type in its memoryuntil battery is disconnected so that that information does not have tobe input again by a user unless other circumstances dictate its inputagain.

Charging and Discharging

A useful feature of preferred embodiments of the present invention isthat the software and processor can calculate and cause the display todisplay the net charging rate or net discharging rate of the battery 14if the battery is being charged and discharged simultaneously. That is,if, say, a light or a radio is being used, say, by being plugged intothe GPO, and the battery is being charged at the same time, by use ofthe external power supply socket 25, then the net charging ordischarging rate is calculated by the processor and then displayed onthe display 41. The software decides in this case to use an appropriatecharge map depending on the net charge or discharge rate. Depending onthe net charge or discharge rate, there may be a rest period asdescribed hereinabove during which the battery voltage is measured so asto assist with capacity calculations.

It will be appreciated by persons skilled in the art that numerousvariations and/or modifications may be made to the invention as shown inthe specific embodiments without departing from the spirit or scope ofthe invention as broadly described. The present embodiments are,therefore, to be considered in all respects as illustrative and notrestrictive.

We claim:
 1. A portable power supply comprising: a housing for receivinga lead-acid battery for removable mounting therein, the housingcomprising spaced-apart walls, an open top and an access cover forclosing the open top and providing access to the removable lead-acidbattery; a computing processor in electrical communication with theremovable lead-acid battery for processing information about theremovable lead-acid battery mounted in the housing; a powered displaypanel disposed on the housing in electrical communication with thecomputing processor for displaying messages or images thereon relatingto the lead-acid battery, and the messages or images displayed includeany of: battery charge percentage, time remaining to dischargecompletion, and battery capacity in Ampere hours; and a plurality ofpower sockets mounted on the housing for providing power to electricaldevices.
 2. The portable power supply in accordance with claim 1 furthercomprising an inverter system for providing alternating current from thebattery, the inverter electrically connected to at least one of thepower sockets.
 3. The portable power supply in accordance with claim 1wherein the selected walls are end walls, and wherein the handles arerecessed in end walls of the housing.
 4. The portable power supply inaccordance with claim 1 wherein the handles include apertures tofacilitate ingress of cooling air from outside the housing into thehousing for cooling the removable battery.
 5. The portable power supplyin accordance with claim 1 wherein the handles include a surface whichcooperates with a finger such that a ramp is provided to guide a fingerinto a radiused head portion disposed at an upper end of the ramp. 6.The portable power supply in accordance with claim 1 further comprisinga user input device including one or more user input buttons forselecting the type of battery based on its construction disposed withinthe housing, the display screen electrically connected to the user inputbuttons displaying differing messages or images depending on selectionof the battery type.
 7. The portable power supply in accordance withclaim 6 wherein the user input device is configured to receive a userselection of battery capacity in Ampere hours.
 8. The portable powersupply in accordance with claim 6 wherein the computing processor isconfigured to receive input, from the user input device, a measure ofbattery capacity in Ampere hours.
 9. The portable power supply inaccordance with claim 8 wherein the computing processor is configured toestimate the time remaining to full discharge of the removable battery.10. The portable power supply in accordance with claim 6 wherein theuser input device is configured to select data regarding theconstruction type of battery from the group consisting of: standardlead-acid, calcium, AGM, and gel for input into the computing processor.11. The portable power supply in accordance with claim 1 wherein atleast one of the power sockets is a USB port for supplying power to anelectronic device.
 12. The portable power supply in accordance withclaim 1 further comprising a DC-to-AC inverter and a 240V/50 Hz or110V/60 Hz General Power Outlet for supplying power to an electricaldevice.
 13. The portable power supply in accordance with claim 12wherein the DC-to-AC inverter is removably mounted in the housing. 14.The portable power supply in accordance with claim 12 wherein the oreach General Power Outlet is mounted on one or more of the walls or lidso that they are recessed therefrom; and one or more access covers isprovided, each access cover for covering a general power outlet so thatby actuating the or each access cover the general power outlet may beaccessed and wherein the cover is generally flush with its respectivewall.
 15. The portable power supply in accordance with claim 14 whereinthe or each access cover extends over a portion of the top wall to aportion of an adjacent side wall so that the or each access cover is inthe form of a gullwing-like shell.
 16. The portable power supply inaccordance with claim 1 wherein the computing processor is configured toconsult relevant voltage maps stored in a storage portion of thecomputer processor which contains certain values of battery chargepercentage corresponding to certain voltage values of the selectedbattery type.
 17. The portable power supply in accordance with claim 1further including a temperature sensor associated with the housing, andwherein the computing processor is configured to receive input from thetemperature sensor to assess the measured temperature against a cutouttemperature, so as to inhibit discharging if the measured temperatureexceeds the cutout temperature.
 18. The portable power supply inaccordance with claim 1 further comprising a charging apparatus having aprocessing system for charging the removable battery.